These days wear-resistant coatings including Fe–TiC composites because of their properties such as high melting point, hardness, and wear resistance are used in different fields such as aerospace, transport, cutting, and abrasive. In situ synthesis of Fe–TiC nanocomposite as a wear-resistant coating by the plasma-spray process is the purpose of this study. Ilmenite concentrate and carbon black were used as raw materials. Three kinds of powders with different conditions were prepared and sprayed on CK45 steel substrates in constant conditions. Microstructure, phase identification, wear resistance, and hardness of coated samples were determined. The results showed that activated sample was synthesized during the plasma spray, but in situ synthesize did not happen for inactive sample which was sprayed by plasma spray. Also, wear resistance and hardness tests showed by synthesis of Fe–TiC composite in coated samples, wear resistance, and hardness were increased.

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